Heat insulating fibrous mass

ABSTRACT

THE INVENTION COMPTEMPLATES THE HOMOGENEOUS DISTRIBUTION OF HARD GRANULES OR PARTICLES THROUGH A MASS OF RESIN-COATED MINERAL FIBERS TO PRODUCE STRUCTURAL UNITS IN THE FORM OF SHEETS OR SLABS COMPOSED OF THE MASS OF MINERAL FIBERS IN LATTICE-WORK FORM, PARTICULARLY GLASS FIBERS AGGLOMERATED WITH THE DRIED AND CURED RESIN BINDER AND HAVING INTERSPERED IN THE MESHES OF THE MASS, THE SEPARATE HARD AND INDEFORMABLE PARTICLES, EITHER IN SOLID FORM SUCH AS SAND OR IN POROUS FORM, SUCH AS PERLITE OR VERMICULITE, WHICH RENDER THE STRUCTURAL UNITS STRONGLY RESISTANT TO PHYSICAL DEFORMATION WHILE ENCHANCING THE HEAT-INSULATING CHARACTERISTICS THEREOF.

July 10, 1973 R ET AL 3,745,060

HEAT INSULATING FIBROUS MASS Original Filed May 6, 1968 8 Sheets-Sheet'1 INVENTOR-S C4 4005 JUME'A/T/'fi 144 4/11! 504/4157 y 1973 C.JUMENTIERETAL HEAT INSULATING FIBROUS MASS Original Filed May 6, 1968 8Sheets-Sheet July 10, 1973 C JUMENT|ER ET AL 3,745,060

HEAT INSULATING FIBROUS MASS 8 Sheets-Sheet 9:

Original Filed May a, 1968 July 10, 1973 C'JUMEN-HER ET AL 3,745,060

HEAT INSULATING FIBROUS MASS Original Filed May 6, 1968 8 Sheets-Sheet 4July 10, 1973 c JUMENTER ET AL 3,745,060

HEAT INSULATING FIBROUS MASS Original Filed May 6, 1968 8 Sheets-Sheet fJuly 10, 1973 QJUMEN'HER ET AL 3,745,060

HEAT INSULATING FIBROUS MASS Original Filed-May 6, 1968 8 Sheets-Sheetr.

July 10, 1973 QJUMENTER ET AL 3,745,060

HEAT INSULATING msnous mss Original Filed May 6, 1968 8 Sheets-Sheet 7July 10, 1973 IER ET AL 3,745,060

HEAT INSULATING FIBROUS MASS Original Filed May 6, 1968 8 Sheets-Sheet aUnited sate; Patent 6 3,745,060 HEAT INSULATING FlBRUlUS MASS ClaudeJumeutier, La Celia Saint Cloud, and Alain Bonnet, fllermont, France,assignors to Compagnie dc Saint-Gabain, Neuilly-sur-Seiue, FranceOriginal application May 6, 1968, Ser. No. 726,706, now Patent No.3,616,030. Divided and this application Dec. 23, 1970, Ser. No. 101,060

Claims priority, application France, May 11 1967,

106,046; May 12, 1967, 106,273; Apr. 18, 1968, 148,483 Int. Cl. E32b5/16 U.S. Cl. 161-170 11 Qlairns ABSTRACT OF THE DESCLQS The inventioncontemplates the homogeneous distribution of hard granules or particlesthroughout a mass of resin-coated mineral fibers to produce structuralunits in the form of sheets or slabs composed of the mass of mineralfibers in lattice-work form, particularly glass fibers, agglomeratedwith the dried and cured resin binder and having interspersed in themeshes of the mass, the separate hard and indeformable particles, eitherin solid form, such as sand, or in porous form, such as perlite orvermiculite, which render the structural units strongly resistant tophysical deformation while enhancing the heat-insulating characteristicsthereof.

This is a division of application Ser. No. 726,706, filed May 6, 1968,Patent No. 3,616,030, Oct. 26, 1971.

The invention relates to the production of plates or sheets shaped froma mass of mineral fibers, particularly glass fibers, agglomerated by abinding agent, which present at the same time both a high insulatingcapacity as well as a high degree of indeformability. According to onecharacteristic of the invention, these plates or shaped sheets areconstituted by a lattice-work or network of fibers which are joined toeach other by a binder and by solid and indeformable particles in theform of unitary granules which are interlocked and encompassedseparately in the meshes of the fiber network and distributed in ahomogeneous fashion therein.

It is another characteristic of the invention that the particles whichare employed are at the same time hard, whole and iudeformable, whilebeing either solid or porous.

It has been determined that While the products of the invention presenta very low tendency to deformation, particularly compression, theyretain strongly the high heat-insulating capacity inherent in the porousstructure of a mass of mineral fibers. This preservation of the highinsulating quality is due to the fact that the hard particles orgranules are in contact with the fibers of the meshes which encompassthem only along points or lines of slight length, and thus there ispractically no formation of thermal conducting paths or bridges betweenthe particles and the fibers.

The high degree of indeformability of the products of the inventionarises from the fact that each particle impedes the local deformation ofthe network in which it is enclosed, and that by reason of thehomogeneous distribution of the particles in the entire mass, thedeformation of the whole of the mass is prevented by the presence of allof these particles.

In a general way, it is possible to select the average granulometry ofthe particles which are used, as a function of the volumetric mass whichis related to the mass of fibers. In all cases, the size of theparticles or granules should be such that they are enclosed within themeshes of the network formed by the fibrous mass. If these meshes arevery fine, small granules or particles of light granulometry are used;if the meshes are large, particles of larger dimensions may be used.

According to one embodiment of the invention, the fibers constitutingthe network may have a mean diameter between 3 microns and 16 microns;the apparent volume-mass characteristic or density of this fibrous massmay range between 25 kg. and 200 kg. per cubic meter, and preferablybetween 35 kg. and 100 kg. per cubic meter; the granulometry of thesolid, whole, indeformable particles may be of the order of 0.10 mm. to0.6 mm. and the proportion by volume of the mass of particles may be ofthe order of 2% to 20%, and preferably 3% to 15% of the total volume ofthe product.

According to another embodiment of the invention, the apparentvolume-mass characteristic or density of the fibrous network may rangebetween 35 kg. and 100 kg. per cubic meter, and the particles enclosedin the meshes of this network may be constituted by grains of sand of agranulometry of the order of 0.10 mm. to 0.40 mm.

Instead of sand, other solid particles may be used, for example, crushedglass, crushed rock, melted coal ashes, etc. The condition which theseparticles must always meet being that they are hard and indeformable.

Another improvement results from the use of hard and indeformablegranules which include empty spaces. Advantageous characteristics areimparted to the structural units of the invention by the use of hardporous or foamed mineral particles, such as perlite or vermiculite. Theproducts resulting from the use of such components are characterized byextremely light weight, high insulating capacity and a high degree ofindeformability.

When use is made of fibrous masses having a slightly elevated specificdensity, the presence of these particles therein, particularly perlite,result in products which evi dence a strong resistance to deformation,particularly compression.

In the modes of execution of the invention with hard porous granules,the constituent fibers of the network may have a mean diameter rangingbetween 3 microns and 16 microns, the apparent volume-masscharacteristic or density of this network may range between 8 kg. andkg. per cubic meter, preferably between 8 kg. and 50 kg. per cubicmeter, with the granulometry of the granules being above 0.1 mm., andpreferably between 0.5 mm. and 5 mm., and the proportion in volume ofthe mass of particles being of the order of 3% to 80%, and preferablybetween 10% and 50% of the total volume of the product.

The quantity of particles which is used per unit of volume of the finalproduct depends on the density of the product and the mechanicalproperties which are sought to be attained. To obtain identicalmechanical properties, for example, identical resistance to crushingunder load, it is desirable that the proportion of particles be greateras the quantity of constituent fibers per unit of volume is lower.Otherwise, for a like quantity of fibers per unit of volume, the greaterproportion of granules results in a higher degree of mechanicalresistance.

It is the object of the invention to provide a method of producingstructural units in the form of plates or shaped sheets of highinsulating capacity and indeformability, as described above. This methodconsists in introducing the hard and indeformable particles, either insolid or porous form, throughout the mass of fibers in homogeneousfashion, by flowing the particles and projecting them into the mass offibers which is treated with a binding agent, by the action of a gaseouscurrent, and by then reducing the volume of said mass in such a way thatthe particles are completely enclosed and interlocked between the fibersafter the binder sets. The reduction of volume may be effectedadvantageously by exerting a suction efi'ect through the mass of fibers.

As a variation, the method may also be executed by introducing all orpart of the binder together with the solid or porous granules orparticles, into the mass of fibers. Thereby a better distribution of thebinder within the network of fibers is obtained. It has been determinedthat the binder introduced with the particles moves from the surfaces ofthe particles towards the fibers and assures the joining of these fibersat their crossing points without the binder remaining in contact betweenparticles and fibers, thereby avoiding all thermal bridges between them.

In accordance with the invention, provision is made to vary the quantityof granules or particles introduced into the mass of fibers, which maybe varied in dependance upon the mechanical characteristics sought to beimparted to the product.

The invention contemplates many different devices for executing theprocedures described above. These devices comprise a distributor,wherefrom the particles flow by gravity, and members, such as blowingnozzles, for producing gas jets, which act on the particles to projectthem into the mass of fibers and distribute them homogeneously in thelatter.

According to one embodiment of the apparatus, the projection ofparticles takes place on one side of the mass of fibers.

According to another embodiment of the invention, the distributor andblower members are arranged around the mass of fibers issuing from theproduction apparatus, and there is provided, under the blower members,an oscillating nozzle or conduit into which passes the mass of fiberswith the particles which have been incorporated in it. The oscillationsof the nozzle or conduit make possible the regular distribution offibers on the cloth or other receiving surface onto which the mass isprojected for the formation of a mat or sheet.

It is the particular objective of the arrangements in accordance withthe invention to secure an efiective homogeneous distribution of theparticles in the mass of fibers. This may be attained by introducing thegranules or particles into the gaseous currents in the form of a sheetof particles which flows in a homogeneous and uniform fashion. This maybe accomplished by feeding the particles onto a distributing surfacesurrounding the mass of fibers, which particles flow in a homogeneos anduniform fashion from the distributing surface in the form of a sheetwhich is subjected to the action of the gaseous currents. One of thefeatures of the invention is that the particles move freely on thedistributing surface in forming a natural flow.

When the fibers are produced by a rotary centrifuge, of the type wellknown in the art, the attenuated fibers gravitate in the form of atorus-shaped mass having a rotary movement. In this case, the particlesmay be projected into the mass of fibers by imparting a rotary movementto the annular sheet of granules which has a component in a directionopposite to the direction of rotary movement of the mass of fibers.

Also, the apparatus in accordance with the invention comprises adistributing member in the form of a crown surrounding the mass offibers with elements which supply the particles onto the crown in theform of threads or streams. The crown has an inclination or slope atleast equal to the slope of collapse or the angle of repose of thegranules so that the several streams form sheets, which, by virtue ofthe positioning of the points of supply of the particles, merge togetherat the rim of the distributor crown to form a continuous and homogeneouslayer of uniform thickness, which is then projected onto the mass offibers by the blowers.

In accordance with another feature of the invention, the elements whichsupply the particles onto the distributor crown are formed by conduitswhich communicate with an apparatus which feeds the particles through aplurality of orifices, beyond which, the thickness of the beds or layersof particles issuing from the several orifices, is maintainedsubstantially the same.

In accordance with another feature of the invention, the apparatussupplying the particles may consist of parallel tubes fitted with screwconveyers which advance and circulate the particles and feed them instreams or layers of substantially constant and adjustable thicknessbeyond the orifices which supply the conduits. The latter are preferablyin the form of sluices or channels. In order to permit the regulation ofthe passage of the particles which enter these conduits or sluices,members in the form of perforated masks may be applied around the supplytubes along the length thereof, which permit any desired adjustment ofthe orifices through which the particles pass.

In another embodiment of the invention, the apparatus for feeding theparticles consists of a tube in the form of a torus, which is disposedadjacent to the inclined wall of the crown, and which contains openingsthrough which the particles flow onto the inclined wall. A helicalmember is provided in the tube for conveying the particles therethrough.

Other objects and purposes of the invention will appear from thefollowing description in conjunction with the accompanying drawings,which illustrate several non-limiting examples, and wherein FIG. 1 is aview of a mass of interlocked mineral fibers, on a greatly enlargedscale, with binding agents incorporated therein,

FIG. 2 is a view similar to FIG. 1, following the compression of themass of fibers in a vertical direction;

FIG. 3 is a view similar to FIG. 1 with the inclusion of separate hardand indeformable particles in the network of the mineral fibers, inaccordance with the invention;

FIG. 4 is a view similar to FIG. 3 following the deformation of the massof fibers by a compressive force of the same intensity as that employedon the mass shown in FIG. 2;

FIG. 5 is a front elevation, with certain parts in section, of anapparatus for executing the invention;

FIG. 6 is a sectional view, with certain parts in elevation, of a secondembodiment of an apparatus in accordance with the invention;

FIG. 7 is a partial view of FIG. 6, on an enlarged scale, at the outletof the receptacle and blower for the hard particles;

FIG. 8 is a front elevation of another embodiment of the invention,illustrating the incorporation of the granules within the mass of fibersissuing from a different form of fiber-producing apparatus;

FIG. 9 is a perspective view of still another embodiment of theinvention;

FIG. 10 is a vertical sectional view through the installation shown inFIG. 9 with certain parts in elevation;

FIG. =11 is a diagrammatic plan view of the distributor shown in FIGS. 9and 10, and indicating schematically the disposition of the conduits orsluices for feeding the hard particles thereto;

FIG. 12 is a vertical sectional view of a portion of the distributorcrown at the outlet end of the supply conduits, illustrating the flow ofthe particles onto the distributor surface;

FIG. 13 is a vertical sectional View along line 13-13 of FIG. 9;

FIG. 14 is a sectional view of one of the perforated masks which aremounted along the supply tubes shown in FIGS. 9 and 10;

FIG. 15 is a side view of the mask shown in FIG. 14;

FIG. 16 is a perspective view of another embodiment of the invention;and

FIG. 17 is a sectional view along line 17-1.7 of FIG. 16.

FIGS. 1 to 4 illustrate graphically the advantageous features of theinstant invention.

FIG. 1 shows a part of a mass of mineral fibers 1 which, as is known,are joined together at cross-points by a binder. Four of thesecross-points are marked A, B, C, D.

If this mass is subjected to a mechanical stress, such as, for example,compression (FIG. 2), it is seen that the thickness of the mesh orlattice-work of fibers decreases, and that the quadrilateral A, B, C, Dis reduced to form quadrilateral A, B, C, D.

FIG. 3 shows the same fibrous structure as that shown in FIGS. 1 and 2,but one in which hard, whole and indeformable particles or granules 2are introduced and interlocked between the meshes of the network offibers. The preceding cross-points are marked A", B", C", D" and occupysubstantially the same relative positions as the cross-points indicatedin FIG. 1. If the mass is subjected to the same compressive stress asthat imposed on the unit shown in FIG. 2, the resulting product isillustrated in FIG. 4. It is seen that the presence of each particleprevents deformation of the mesh in which it is enclosed, the points A,B'", C' D' remaining in the same positions as points A", B", C", D", andthat the assembly itself undergoes a decrease in thickness of much lessextent than that in the case illustrated in FIG. 2.

FIG. 5 illustrates one embodiment of an apparatus for obtaining afibrous mass according to the invention as shown in FIGS. 3 and 4.

Fibers 2, for example glass fibers, are produced by a machine 3, whichmay be a centrifuge body rotating at high speed and having a peripheralwall provided with orifices through which are projected by centrifugalforce threads of material which are attenuated into fibers in a mannerwell known in the art. Spray guns 4 project a binding agent onto themass of fibers and a nozzle 5 directs a jet of air onto said mass, todirect it toward the zone where hard granules or particles 12 areintroduced. The particles are contained in a receptacle 6, whose bottomis provided with ledges or movable shutters 7 with a feed regulatordevice 8. The particles issuing from the receptacle pass into a rotatingdrum 9 which assures a regular outflow of the particles wherefrom theyflow by gravity through conduit 10. One or several nozzles 11 project ajet of air under pressure onto the particles in order to direct themtoward the mass of fibers. A homogeneous spatial distribution of all theparticles within the mass of fibers is assured by controlling thestrength and direction of the air jet.

Spray guns 13 may project a binder onto the surfaces of particles beforethey are introduced into the mass of fibers.

The mass of fibers with the particles incorporated therein then passesonto an endless cloth band or other airpermeable conveyor 14, underwhich is arranged a suction casing 14a to form a pad or mat 15 of thedesired thickmess. The passage of this pad into an oven results inpolymerization and hardening of the binder and cohesion of theinterengaging fibers of the mat at their points of crossing contacts.

In the embodiment shown in FIGS. 6 and 7, particles 12 are distributedfrom an annular container 16 arranged coaxially with respect to the massof fibers 2 issuing from a centrifuge 17. The outflow of these particlesis controlled by regulating elements 18. The particles flowing fromannular orifice 19 of the distributor are subjected to the action of acircular blower 20 which assures their homogeneous spatial distributionin the entire mass of fibers.

An annular conduit or tuyere 21 is disposed below the circular blower 20through which the mass of fibers passes, and an oscillating movement isimparted to the former. The moving conduit 21 makes possible a regulardistribution of fibers on the endless air-permeable conveyor 14 for thepurpose of forming the mat thereon.

In this embodiment the binder is introduced into the combined mass offibers and granules by means of spray guns 22.

In the embodiment shown in FIG. 8, the fibers are produced by drawingout the molten glass threads flowing from fixed spinning orifices 23.These threads, transformed into fibers, are directed to the interior ofhood or funnel 24 and are impregnated with a binding agent by means ofspray guns 25 before dropping onto endless conveyor member 26, underwhich is disposed the suction casing 27.

The solid indeformable particles issuing from an apparatus, such asshown in FIG. 5, are led to the interior of the hood 24 where they dropin a free fall in order to be distributed in the mass of fibers by meansof a gas current issuing from one or several nozzles 28.

In the embodiments shown in FIGS. 9 to 17, the apparatus for theproduction of the glass fibers 2 is indicated at 17, and is similar tothat shown generally in 'FIG. 6. This apparatus 17 consists of arotatable centrifuge operating at high speed with a peripheral wallhaving a plurality of orifices through which are projected the moltenfilaments of glass which are attenuated into the form of fibers.

In the apparatus shown in FIGS. 9 to 15, the solid particles, forexample sand, which are introduced into the mass fibers, are supplied bytwo hoppers 30 from which they flow into a pair of tubular conduits 31.A conveyor screw 32 is provided in each of the conduits, the diam eterof which is less than the internal diameter of the conduits. The twoscrews 32 are maintained in synchronism by means of a motor-reducerdrive assembly 4-3.

The tubular conduits 311 have orifices 33 (FIG. 13) disposed along thelowermost portions of their cylindrical surfaces and through which flowthe particles which are conveyed by the screws 32. A sluice or conduit34 is disposed opposite each orifice 33. The particles fiow along thelength of each conduit and are discharged in the form of jets onto thedistributor crown 35. This crown is disposed coaxially with the rotarycentrifuge l7 and presents an oblique wall 36 towards the interior, theslope of which is at least equal to the angle of repose of the granulesor particles.

The conduits or channels 34 are so disposed that the zones of impact 37of the particles on the oblique wall 36 of the crown 35 are such thatthe particles fiow freely on this wall, forming sheets 38 which spreadout and reunite along the length of the lower edge of the wall 36, (FIG.12), thus forming a homogeneous and continuous sheet. The gaseous jetissuing from the annular orifice 40, provided at the base of thedistributor 35 with the annular chamber 41, acts on this annular sheetof granules. The gas is introduced into this chamber through conduits 42which are disposed obliquely in such a fashion that the particles areprojected into the mass of fibers in the opggsite rotary direction fromthat of the rotating mass of ers.

The mass of fibers in which the particles are thus distributed inhomogeneous fashion then passes into a conduit or tuyere 44 whichexecutes an oscillating movement about a horizontal axis 45, therebypermitting a uniform distribution of the fibers onto a receiving webbelow it, on which is formed a mat, these fibers having been impregnatedpreviously with a bindner by means of spray guns, as shown in thearrangements described above.

FIG. 11 shows the disposition of the conduits or channels 34, theinclinations of which are adjusted in a manner that their slope permitsthe natural flow of the particles (a slope of at least 30 in the case ofsand), and the directions of which are such that the zones of impactlead to the obtention of a continuous and homogeneous sheet, asdescribed above and as shown in FIG. 12. These troughs are mounted onsupports 46 disposed above the distributor crown in a fashion tominimize the obstruction of the apparatus.

The disposition of the conveying screws 42 and their rotary speed aresuch that a stream of particles of substantially uniform thickness isobtained below the assembly of outlet orifices 33 of tubular conduits31. How ever, to obtain the proper delivery from each channel 34, whichis fed from each of the orifices, masks 47, having openings 4-8 ofdifferent diameters, are resiliently mounted on the tubular conduits 31in overlying relation to openings 33 therein. These masks of springymaterial may be turned to place an orifice of predetermined sizeopposite each outlet opening 33 of the tubular conduit according to therate of discharge sought to be attained. An abutment or lug 49 isprovided on the inside of each mask for selective cooperation with oneof a plurality of grooves or notches 50 on the periphery of the conduits31, which permits placing the apertured mask in correctly alignedposition for any selected opening 48 in the latter.

In order to permit the evacuation of any excess particles or granulesand to avoid jamming or choking of the conduits 31, the end 52 of eachconduit is provided with openings 51 which permits the elimination ofthese excess particles.

The quantity of granules or particles discharged from the distributor isa function of the diameter of the holes 48 in the masks and the speed ofrotation of the feed screws 32, the latter being adjusted for all theholes, with the exception of the openings 51 which are effective onlywhen the conduits are too full. The latter serve to discharge particlesonly when the holes 33 and 48- become obstructed or when there is astrained operation, thereby avoiding a breakage of the feed screws.

In the modified embodiment shown in FIGS. 16 and 17, the particles arefed from a hopper 53 into an annular conduit 54 arranged in the form ofa torus, in which operates a helical core-less feed member 55 which isretated by a. motor-reducer device 56. This conduit is disposedcoaxially with the rotary centrifuge adjacent to the inclined wall 36 ofthe distributor crown 35, which operates in the same manner as describedabove in conjunction with FIGS. 9 to 15. The conduit 54 is provided withorifices 57 (FIG. 17), through which the particles flow onto the wall 36for forming a continuous sheet of uniform thickness at the internal rim39 of the distributor crown.

Any suitable polymerizable resins may be used as binding agents,examples of which are set forth below. Furthermore, variations may bemade in the details of the apparatus, for example, in the character ofthe air-permeable conveyor for receiving the mass of fibers combinedwith a resin binder and hard particles distributed therethrough. As setforth above, the latter may be in the form of hard solid andindeformable granules, such as sand, or these granules may be hard andindeformable with voids therein such as foamed or porous granules ofperlite or vermiculite. The invention also contemplates the use of hardand indeformable light particles which are interlocked in the meshes ofthe fibrous network, such as crushed, foamed or porous glass.

Below are given examples of products of glass fibers according to theinvention as well as comparative data, between these products and thesame products which do not include hard and separate unitary solid orfoamed indeformable particles, from the point of view of heatinsulatingcapability and resistance to deformation.

(b) Mean diameter of fibers: 6 microns Nature of binder: Phenolformaldehyde resin (d) Nature of particles: Sand (e) Mean diameter ofgrains: 0.2 mm.

Load

required Coefficient to reduce of thermal thickness conductivof productComposition of ity, KcalJ by Product product mm, C. kg./1n.

Without sand ..{g 55 1 28. 7 470 Fibers: 38 kg./m.

With sand Resin: 2 kg./m. 30. 2 880 Sand: 60 kg./m.

NorE.Kg./m. is abbreviation for kg. per cubic meter; kgJm. isabbreviation for kg. per square meter.

It is to be noted that while the products have substantially the sameinsulating power, the load necessary to obtain the same reduction inthickness in the product in accordance with the invention is nearlydouble.

EXAMPLE II Identical with those of Example I:

(a) Composition of the glass (b) Mean diameter of the fibers (0) Natureof the binder ((1) Nature of the granules or particles (c) Mean diameterof the granules Load required Coetficient to reduce of thermal thicknessconduetivof product Composition of ity, KcalJ by 25%, Product product m.C. kgJm.

Fibers: 64.5 k ./m. Without sand 5.5 g 28.0 1, 510

Fibers: 54.5 kgJm With sand ..{Resln: 5.5 kgJmfimn} 31.0 2, 300 Sand:kg./m.

(2.) Composition of the glass: Percent SiO 61.3 A1 0 5.5 F 0 0.6 CaO 7.3MgO 3.1 Na O 13.9 K 0 1.9 B 0 2.9 BaO 3.2

(b) Mean diameter of the fibers: 12 microns (0) Nature of binder: Phenolformaldehyde resin (d) Nature of granules: Sand (e) Mean diameter ofgranules: 0.2 mm.

Load required to reduce thickness oi product by Composition of 2 Productproduct kgJm.

Fibers: 99 kg. m.

Without sand 11 j 9,000

ibers: 99 kgJmfi- With sand Resin: l1 kg.lm. 16,000

Sand: 90 kg./m.

Set forth below are two examples of products of glass fibers withperlite and vermiculite, according to the in vention, these examplesshowing, comparatively, the differences from the point of view ofinsulating value and resistance to deformation between these productsand the same products which do not include these particles.

9 EXAMPLE IV-Continued (a) Composition of glass: Percent 0.2

(b) Mean diameter of fibers: 6 microns (c) Nature of binder: Phenolformaldehyde resin (d) Nature of grains: Perlite (e) Diameter of grains:0.1 mm. to 2 mm.

Load

required Coefliclent to reduce of thermal thickness conductivof productComposition of ity, KcaLl by 25%,

Product product m.7\, C. kgJm I Without perlite 2 {52 3 Fibers: 36kgjmfin With perlite Resin: 4 kg./m. 30.0 2, 200

Perlite: 18 kgJml- It is to be noted that while both products havesubstantially the same insulating capacity, the load required to attainthe same reduction in thickness is nearly tripled for the product inaccordance with the instant invention.

We claim:

1. A heat-insulating product composed of a mass of mineral fibersagglomerated with a binder and characterized by a high insulating valueand high resistance to compression and mechanical deformation,comprising a mass of mineral fibers arranged in an intersecting networkof fibers agglomerated together at their intersecting points with ahardened binder and having separate spaced mineral particles which arehard and indeformable and which are homogeneously interspersed andinterlocked in the spaces between the intersecting fibers and in contactwith a plurality of said intersecting fibers within said spaces, toimpose a limited capability of deforming movement thereto whileretaining some of the air voids therebetween.

2. A product as set forth in claim 1 wherein the mineral fibers arefreshly formed and attenuated glass fibers having mean diameters rangingfrom 3 microns to 16 microns, the density of the mass of fibers rangesfrom about 25 kg. to 200 kg. per cubic meter, the granulornetry of thehard particles ranges from about 0.10 mm. to 0.60 mm. with theproportion of solid particles ranging from about 2% to 20% of the totalvolume of the product.

3. An article as set forth in claim 1 wherein the hard and indeformableparticles are solid and full.

4. An article as set forth in claim 3 wherein the particles are grainsof sand.

5. An article as set forth in claim 1 wherein the hard and indeformableparticles have void spaces therein.

6. An article as set forth in claim 5 wherein the particles are ofperlite.

7. An article as set forth in claim 5 wherein the particles are ofvermiculite.

8. A product as set forth in claim 5 wherein the mineral fibers arefreshly formed and attenuated glass fibers having mean diameters rangingfrom 3 microns to 16 microns, the density of the mass of fibers rangesfrom about 8 kg. to kg. per cubic meter, the granulometry of the hardporous particles averages above 0.1 mm. with the proportion of particlesranging from 3% to 80% of the total volume of the product.

9. A product as set forth in claim 5 wherein the mineral fibers arefreshly formed and attenuated glass fibers having mean diameters rangingfrom 3 microns to 16 microns, the density of the mass of fibers rangesfrom about 8 kg. to 50 kg. per cubic meter, the granulometry of the hardporous particles ranges from about 0:5 mm. to 5 mm., with the proportionof particles ranging from 10% to 50% of the total volume of the product.

10. A product as set forth in claim 1 wherein the mineral fibers arefreshly formed and attenuated glass fibers having mean diameters rangingfrom 3 microns to 16 microns, the density of the mass of fibers rangesfrom about 35 kg. to kg. per cubic meter, the granulometry of the hardparticles ranges from about 0.10 mm. to 0.60 mm., with the proportion ofsolid particles ranging from about 3% to 15% of the total volume of theproduct.

11. A product as set forth in claim 10 wherein the hard particles aregrains of sand having a granulometry ranging from 0.10 mm. to 0.40 mm.

References Cited UNITED STATES PATENTS 3,025,202 3/1962 Morgan et a1.161-158 UK 1,354,025 9/1920 Coryeli 161162 X 2,972,554 2/ 1961 Muskat eta1 117-76 3,199,714 8/1965 Bodendorf et al. 22-0--9 3,515,624 6/1970Garnero 161-158 X 3,562,370 2/1971 Shannon 264-1 12 WILLIAM A. POWELL,Primary Examiner US. Cl. X.R.

